Channel cover

ABSTRACT

A channel cover for an aluminum extrusion member or other formed structural member having a channel longitudinally formed in a side of the member includes an upper portion or member having an exterior surface, a first side portion or member connected to and extending from the upper member, a second side portion or member connected to the upper member opposite from the first side member at a first distance from the first side member, and a lower member having an exterior surface, the first side member attaching to the lower member, and the second side member attaching to the lower member at a second distance from the first side member, the second distance being different from the first distance. In a preferred embodiment, the first and second side members converge towards each other as they extend from the upper member towards the lower member. The portion of the channel cover between the upper and lower members and the first and second side members can either be solid, or alternatively each of the members can have an interior surface with their interior surfaces defining a hollow, interior channel.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to the field of awnings and other framed, fabric structures, and more particularly to the field of framing members having an open channel therein used to construct such structures.

BACKGROUND

An awning is an architectural fabric projection that is typically attached to the side of a building to provide cover for individuals passing near the building, or to provide cover or protection for the building itself such as providing cover for windows in the building, or to provide a surface for displaying a message such as a business name or advertising. The awning includes a frame and a fabric covering for the frame that is secured to the frame.

The frame can be formed from frame members that may be extruded aluminum or other formed structural frame members. FIG. 1 illustrates a known frame member 10. Typically, each frame member 10 is an elongated shape having a top side, two side walls, and a bottom wall. In some cases, the top side may include a lengthwise or longitudinally formed opening that provides access to a channel 18 within an interior space of the frame member. The fabric 12 may be inserted through the opening into the channel and secured therein with a fastener 14, such as a staple or screw. The channel may have a web extending between the two side walls that provides a platform for securing the fabric 12.

Where a channel is provided, a channel cover 16 may be inserted into the channel after the fabric is secured. The channel cover 16 is typically an elongated extrusion as shown in FIG. 1. The channel cover may assist in retaining the fabric within the channel, may seal the channel opening, thereby preventing rainwater from leaking through the awning or from degrading the fabric fasteners. The channel cover may also be aesthetically desirable to conceal staples or other fasteners used to fasten the fabric in the channel opening so that the awning has a clean, finished appearance.

A known channel cover is shaped as shown in FIG. 1, having an upper cap, a lower cap, and two parallel side bars connected or reinforced by a web positioned generally parallel to and intermediately between the upper and lower caps. Another known channel cover similar to that of FIG. 1 is disclosed in U.S. Pat. No. 5,577,352 that also has parallel sides but is not reinforced by an intermediate web. Also known is a channel cover having notched sides but a solid cross-section as in U.S. Pat. No. 4,926,605.

So that awnings may be fashioned having a range of silhouettes, frame members are commercially available in a variety of shapes and sizes having cross-sections that differ from the cross-section illustrated in FIG. 1. Depending on the frame member, the size and shape of the channel may vary, and the size and shape of the opening providing access to the channel may vary. Conventional channel covers are typically designed to mate only with a particular frame member or with frame members made by a particular manufacturer, but not other frame members.

From the above, it is apparent that a need exists for a universal channel cover that will fit a variety of channel openings in frame members having a range of shapes and sizes.

SUMMARY

A channel cover is disclosed herein that meets the above mentioned need. The channel cover includes an upper member or segment having an interior surface, a first side member or segment extending from the interior surface of the upper member, a second side member or segment opposite the first side member extending from the interior surface of the upper member at a first distance from the first side member, and a lower member or segment having an interior surface, the first member attaching to the interior surface of the lower member, and the second side member attaching to the interior surface of the lower member at a second distance from the first member. The first and second members converge towards each other as they extend from the upper member towards the lower member, whereby the side members define a hollow interior channel.

In an exemplary embodiment, the side members remain spaced apart at the lower surface at a second distance which is different from, and preferably less than, the first distance. In another exemplary embodiment, the side members converge together such that they contact each other at the interior surface of the lower member.

In yet another exemplary embodiment, the channel cover includes upper and lower portions and first and second side portions, the first and second side portions converging towards each other as they extend from the upper portion towards the lower portion, the upper and lower portions and the first and second side portions defining a solid center or core instead of defining a hollow interior channel.

Other systems, devices, features, and advantages of the disclosed channel cover will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, devices, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the disclosed channel cover can be better understood with reference to the attached drawings, FIGS. 1-3. The components in the drawings are not necessarily to scale, emphasis is instead placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals do not need corresponding parts throughout the several views. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alterations, modifications, and equivalents.

FIG. 1 is a perspective view of a prior art channel cover inserted into an aluminum extrusion or other formed structural frame member.

FIG. 2 is a cross-sectional view of an exemplary embodiment of the channel cover of the present disclosure.

FIG. 3 is a cross-sectional view of the channel cover of FIG. 2 inserted into an aluminum extrusion or other formed structural frame member.

FIG. 4 is a cross-sectional view of another exemplary embodiment of the channel cover of the present disclosure.

FIG. 5 is a cross-sectional view of yet another exemplary embodiment of the channel cover of the present disclosure.

DETAILED DESCRIPTION

As is described above, a need exists for a channel cover that may be used with a variety of frame members having channels and openings of varying sizes and shapes. The channel cover of the present disclosure is directed to such a need and is shaped such that the channel cover universally fits within a wide range of frame members.

FIG. 2 illustrates an exemplary channel cover of the present disclosure. The channel cover 20 includes an upper member or segment 22, a lower member or segment 24, a first side member or segment 26, and a second side member or segment 28. The channel cover may be created by extrusion, such that the upper member 22, the lower member 24, the first side member 26, and the second side member 28 are integrally connected to each other and form a unitary piece. In some embodiments, the channel cover 20 may be extruded from a flexible material such as a plastic or elastomeric material to facilitate inserting the channel cover 20 into the frame member 10. For example, the channel cover 20 may be extruded polyvinyl chloride (PVC).

The upper member 22 may have an upper proximal flange 30, an upper distal flange 32, and an upper bridge 34 that connects the upper proximal flange 30 to the upper distal flange 32. An exterior-facing surface 36 of the upper member 22 may be convex and an interior-facing surface 38 of the upper member may be substantially planar, as illustrated in FIG. 2. In other embodiments, the surfaces 36 and 38 of the upper member 22 may have other shapes.

Likewise, the lower member 24 may have a lower proximal flange 40, a lower distal flange 42, and a lower bridge 44 connecting the lower proximal flange and the lower distal flange. An exterior-facing surface 46 of the lower member 24 may be convex and an interior-facing surface 48 of the lower member may be substantially planar, as shown in FIG. 2. In other embodiments, the surfaces 46 and 48 of the lower member 24 may have other shapes.

The first side member 26 connects the upper member 22 and the lower member 24. As shown in FIG. 2, the first side member 26 may be inwardly spaced from a proximal end 50 of the upper member 22 to create the upper proximal flange 30, and may also be inwardly spaced from the proximal end 52 of the lower member 24 to create the lower proximal flange 40. To connect the upper and lower members, the first side member 26 has an upper end 54 extending downward from a proximal end 58 of the upper bridge 34, and a lower end 56 extending upward from a proximal end 60 of the lower bridge 44. The first side member 26 has an exterior-facing surface 62 that may be substantially planar and an interior-facing surface 64 that may be substantially planar, as shown in FIG. 2. In other embodiments, the surfaces 62 and 64 of the first side member 26 may have other shapes.

The second side member 28 is positioned opposite and spaced apart from the first side member. The second side member 28 connects the upper member 22 and the lower member 24. As shown in FIG. 2, the second side member 28 may be inwardly spaced from a distal end 66 of the upper member 22 to create the upper distal flange 32, and the second side member 28 may be inwardly spaced from the distal end 68 of the lower member 24 to create the lower distal flange 42. To connect the upper and lower members, the second side member 28 has an upper end 70 extending downward from a distal end 74 of the upper bridge 34, and a lower end 72 extending upward from a distal end 76 of the lower bridge 44. The second side member 28 has an exterior-facing surface 78 that may be substantially planar and an interior-facing surface 80 that may be substantially planar, as shown in FIG. 2. In other embodiments, the surfaces 78 and 80 of the second side member 28 may have other shapes.

The first side member 26 may be positioned such that its lower end 56 is more inwardly spaced than its upper end 54. Likewise, the second side member 28 may be positioned such that its lower end 72 is more inwardly spaced than its upper end 70. The distance between the upper end 54 of the first side member 26 and an upper end 70 of the second side member 28 exceeds the distance between the lower end 56 of the first side member 26 and a lower end 72 of the second side member 28. Thus, the first side member 26 and the second side member 28 are not parallel. They converge towards each other as they extend from the upper member 22 towards the lower member 24, as shown in FIG. 2. In the embodiment of FIG. 2, while the side members are convergent towards the lower member, they remain spaced apart at the lower member, though they need not be spaced apart, as discussed further below.

In the embodiment of FIG. 2, the exterior surfaces 36 and 46 of the upper member 22 and the lower member 24 have a non-planar, convex shape. In other embodiments these surfaces may have other shapes. For example, one or both surfaces may have a planar shape. The exterior surface of the lower member may have a concave shape. The exterior surfaces of the side members 26 and 28 are also shown to have planar surfaces. They, too, may have other shapes. Similarly, the interior surfaces of the side members 26 and 28 are shown to be planar, but they may also have other shapes. One or more of the exterior surfaces 62 and 78 of the side members 26 and 28 and the interior surfaces of the upper member 22, lower member 24, and side members 26, 28 may be non-planar. For example, the shape may be concave, convex, ribbed or some other shape.

The staple channel cover 20 may be extruded so that the members have varying lengths. For example, as shown in FIG. 2, the length of the upper member 22 from distal end 50 to distal end 66 exceeds the corresponding length of the lower member 24 from distal end 52 to distal end 68, while the length of the first side member 26 is substantially the same as the length of the second side member 28. In other embodiments, the members may have different lengths than what is shown in FIG. 2. For example, the length of the upper member 22 may be the same as the corresponding length of the lower member 24.

As shown in FIG. 2, the interior-facing surfaces 38, 48, 64 and 80 form a hollow channel 86. The channel 86 does not have a cross-member or web extending between any of the interior-facing surfaces. This allows for greater compressibility and flexibility between the side members 26 and 28 than allowed by prior channel cover designs having an intermediate web between the side members such as that illustrated in FIG. 1. As noted above, the interior surfaces forming the channel 86 may be planar, thus forming a multi-sided channel. The hollow channel 86 of FIG. 2 has a trapezoidal cross-section. As illustrated in FIG. 4 below, it may also have a V-shaped cross-section. Other cross-sectional shapes for the hollow channel 86 are possible, such as a circular cross-section, or a cross-section having one or more concave or convex sides. In other embodiments, the hollow channel 86 may have other shapes.

In the embodiment of FIG. 2, the interior-facing surface 38 of the upper member 22 is substantially parallel to the interior-facing surface 48 of the lower member 24, giving the channel 86 a cross-section that is substantially trapezoidal in shape. In embodiments where the interior-facing surface 38 of the upper member 22 is not substantially parallel to the interior-facing surface 48 of the lower member 24, the channel 86 may be quadrilaterally shaped. In other embodiments, the hollow channel 86 may have other shapes.

The operation of the channel cover 20 will now be described with reference to FIG. 3. FIG. 3 illustrates a frame member 10 having a channel 18. Fabric 12 may be inserted through opening 19 into the channel 18 and may be secured to the frame member 10 using a fastener 14. The fabric 12 may be secured to the frame member using, for example a staple, or may be secured using any other type of fastener and fastening method known in the art, such as screws or nails.

After the fabric is secured, the channel cover 20 may be inserted into the opening 19 over the fabric 12. So that the lower member 24 may pass through smaller openings 19, the lower member 24 has a shorter length than the upper member 22. To facilitate inserting the channel cover 20 through smaller openings 19, the exterior-facing surface 46 of the lower member 24 is convex, and the lower proximal flange 40 and the lower distal flange 42 are flexible so they may bend as the lower member 24 is inserted. The converging shape of the side members 26 and 28 also facilitates insertion. Because the channel 86 does not contain a cross-member, the side members 26 and 28 may flex inward so that the channel cover 20 may be inserted through channel openings of narrow width. Once inserted, the upper member 22 of the channel cover acts as a cap with the upper proximal flange 30 and the upper distal flange 32 resting on the fabric 12 over the frame member 10 to prevent the channel cover 20 from slipping through the opening 19. The extended length of the upper member 22 further prevents the channel cover 20 from slipping through the channel opening defined by the inner ends 19 of the top walls. Once inserted, the convex exterior-facing surface 36 of the upper member 22 minimizes the volume of water entering the channel 18.

FIG. 4 illustrates another embodiment of the channel cover of FIG. 2 in which like numerals represent like parts or components. In the embodiment of FIG. 4, the side numbers 26 and 28 converge towards each other as they extend from the upper member 22 such that they contact each other where they connect to the lower member 24. As a result, the cross-section of the hollow inner channel 86 is V-shaped.

In yet a further embodiment, illustrated in FIG. 5, the channel cover 20 can be provided without the hollow channel 86, thus having a solid center or core 90. In this embodiment, the elements of the channel cover that correspond to the elements of the embodiment of FIG. 2 are provided with like reference numerals. The channel cover 20 includes an upper portion 22 having an exterior surface 36 as well as a proximal end 50 and a distal end 66 along with a lower portion 24 having an exterior surface 46 and a corresponding proximal end 52 and distal end 68. A first side portion 26 having an exterior surface 62 extends between the upper portion 22 and the lower portion 24. A second side portion 28 is provided opposite the first side portion 26, the second side portion 28 also extending between the upper portion 22 and the lower portion 24. The first side portion 26 is inwardly spaced from the proximal end 50 of the upper portion 22 and the corresponding proximal end 52 of the lower portion 24. Likewise, the second side portion 28 is also inwardly spaced from the distal end 66 of the upper portion 22 and the corresponding distal end 68 of the lower portion 24. Preferably, the first and second side portions 26 and 28 converge towards each other as they extend from the upper portion 22 towards the lower portion 24. The portion of the channel cover 20 between the upper and lower portions 22 and 24 and the first and second side portions 26 and 28 is filled in thus providing the channel cover 20 with a solid center or core 90. Since this embodiment does not include the hollow channel 86 described in connection with the prior embodiments, the channel cover 20 of this embodiment is preferably made of a soft material allowing for deformation of its solid center or core 90 when the channel cover 20 is inserted into a longitudinal channel 18 of an aluminum extrusion member 10 or other formed structural member.

Due to its shape, the channel cover 20 of the present disclosure may be used with a variety of frame members 10 having openings 19 that vary in size. The channel cover 20 may also be used with a variety of fabrics 12 having different weights. The channel cover 20 may be manufactured in a variety of colors to complement the color of the fabric 12.

Particular embodiments of the channel cover 20 have been disclosed in the foregoing description and drawings for purposes of example. It should be emphasized that the above-described embodiments, particularly, any “preferred” embodiments, are merely possible examples of implementations, and merely set forth a clear understanding of the principles of the channel cover disclosed herein. Those skilled in the art will understand that variations and modifications can be made without departing from the spirit and scope of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. 

1. A channel cover for an aluminum extrusion or other formed structural member having a channel longitudinally formed in a side of the member comprising: an upper member having an upper proximal flange, an upper distal flange, and an upper bridge connecting the upper proximal flange to the upper distal flange; a lower member having a lower proximal flange, a lower distal flange, and a lower bridge connecting the lower proximal flange to the lower distal flange; a first side member having an upper end and a lower end, the upper end connecting to a proximal end of the upper bridge and the lower end connecting to a proximal end of the lower bridge; and a second side member having an upper end and a lower end, the upper end connecting to a distal end of the upper bridge and the lower end connected to a distal end of the lower bridge; wherein a first distance that is the distance between the upper end of the first side member and the upper end of the second side member exceeds a second distance that is the distance between the lower end of the first side member and the lower end of the second side member, and wherein the upper bridge, the lower bridge, the first side member, and the second side member have interior surfaces that define a hollow, interior channel.
 2. The channel cover of claim 1, wherein the interior surfaces of the first and second side members contact each other above where they connect to the lower bridge of the lower member.
 3. The channel cover of claim 1, wherein the inner surface of at least one of the upper member, lower member, first side member and second side member is non-planar.
 4. The channel cover of claim 1, wherein the inner surface of at least one of the upper member, lower member, first side member and second side member is planar.
 5. The channel cover of claim 1, wherein an exterior surface of at least one of the upper member, lower member, first side member and second side member is non-planar.
 6. The channel cover of claim 1, wherein an exterior surface of at least one of the upper member, lower member, first side member and second side member is planar.
 7. The channel cover of claim 1, wherein each of the upper member and the lower member has an exterior surface, and at least one of the exterior and interior surfaces of the upper member and the lower member are non-planar and are not parallel to each other.
 8. The channel cover of claim 1, wherein a length of the first side member is substantially the same as a length of the second side member.
 9. The channel cover of claim 1, wherein a length of the upper member exceeds a length of the lower member.
 10. The channel cover of claim 1, wherein a length of the upper member does not exceed a length of the lower member.
 11. The channel cover of claim 1, wherein the first side member is inwardly spaced from a proximal end of the upper member to form the upper proximal flange and inwardly spaced from a proximal end of the lower member to form the lower proximal flange, and the second side member is inwardly spaced from a distal end of the upper member to form the upper distal flange and inwardly spaced from a distal end of the lower member to form the lower distal flange.
 12. A channel cover for an aluminum extrusion member or other formed structural member having a channel longitudinally formed in a side of the member comprising: an upper portion having an exterior surface and a proximal end and a distal end and a length from the proximal end to the distal end; a lower portion having an exterior surface and a proximal end and a distal end and a length from the proximal end to the distal end; a first side portion having an exterior surface, the first side portion extending between the upper portion and the lower portion and having a length therebetween; a second side portion, opposite from the first side portion, having an exterior surface, the second side portion extending between the upper portion and the lower portion and having a length therebetween; wherein the first and second side portions converge towards each other as they extend from the upper portion towards the lower portion.
 13. The channel cover of claim 12, wherein the upper portion, lower portion and first and second side portions define a solid core.
 14. The channel cover of claim 12, wherein the exterior surface of at least one of the upper portion, lower portion, first side portion and second side portion is non-planar.
 15. The channel cover of claim 12, wherein the exterior surface of at least one of the upper portion, lower portion, first side portion and second side portion is planar.
 16. The channel cover of claim 12, wherein the length of the first side portion is substantially the same as the length of the second side portion.
 17. The channel cover of claim 12, wherein the length of the upper portion exceeds the length of the lower portion.
 18. The channel cover of claim 12, wherein the length of the upper portion does not exceed the length of the lower portion.
 19. The channel cover of claim 12, wherein the first side portion is inwardly spaced from a proximal end of the upper portion and from a proximal end of the lower portion, and the second side portion is inwardly spaced from a distal end of the upper portion and from a distal end of the lower portion.
 20. The channel cover of claim 19, wherein the first side portion has a length that is substantially the same as a length of the second side portion.
 21. The channel cover of claim 12, wherein each of the upper portion, lower portion, first side portion and second side portion has an interior surface and the interior surfaces of the portions define a hollow, interior channel.
 22. The channel cover of claim 21, wherein the interior surfaces of the first and second side portions contact each other above where they connect to the lower portion.
 23. The channel cover of claim 21, where the interior surface of at least one of the upper portion, lower portion, first side portion and second side portion is non-planar.
 24. The channel cover of claim 21, where the interior surface of at least one of the upper portion, lower portion, first side portion and second side portion is planar.
 25. The channel cover of claim 21, wherein at least one of the interior and exterior surfaces of the upper portion and the lower portion are non-planar and not parallel to each other.
 26. The channel cover of claim 21, wherein the interior surfaces of the upper portion and the lower portion are substantially planar and substantially parallel to each other.
 27. The channel cover of claim 21, the upper portion further comprising a proximal flange, a distal flange, and a bridge connecting the proximal flange and the distal flange, and the lower portion further comprising a proximal flange, a distal flange, and a bridge connecting the proximal flange and the distal flange, wherein the first side portion connects a proximal end of the bridge of the upper portion to a proximal end of the bridge of the lower portion, and the second side portion connects a distal end of the bridge of the upper portion to a distal end of the bridge of the lower portion.
 28. The channel cover of claim 27, wherein the length of the first side portion is substantially the same as a length of the second side portion.
 29. The channel cover of claim 21, wherein the interior surface of the upper portion is substantially planar, the interior surface of the lower portion is substantially planar, the interior surface of the lower portion being substantially parallel to the interior surface of the upper portion, the interior surface of the first side portion is substantially planar, and the interior surface of the second side portion is substantially planar.
 30. A channel cover for an aluminum extension or other formed structural member having a channel longitudinally formed in a side of the member comprising: an upper member having an exterior surface, the upper member including an upper proximal flange and an upper distal flange; a lower member having an exterior surface, the lower member including a lower proximal flange and a lower distal flange, wherein a length of the upper member exceeds a length of the lower member; a first side member having an exterior surface, the first side member including an upper end and a lower end, the upper end connecting to the upper member at a location inwardly of an end of the upper proximal flange, and the lower end connecting the lower member at a location inwardly of an end of the lower proximal flange; and a second side member having an exterior surface, the second side member including an upper end and a lower end, the upper end connecting to the upper member at a location inwardly of an end of the upper distal flange, and the lower end connecting to the lower member at a location inwardly of an end of the lower distal flange, wherein a length of the second side member is substantially the same as a length of the first side member, and wherein a distance between the upper end of the first side member and the upper end of the second side member exceeds a distance between the lower end of the first side member and the lower end of the second side member.
 31. The channel cover of claim 30, wherein the upper member, lower member and first and second side members define a solid core.
 32. The channel cover of claim 30, wherein each of the upper member, lower member and first and second side members has an interior surface and the interior surfaces of the upper member, the lower member, the first side member, and the second side member define the boundary of a hollow, interior channel.
 33. The channel cover of claim 32, wherein at least one of the interior and exterior surfaces of the upper member and the lower member are non-planar and not parallel. 